Aboveground waterproofing boards, systems, and methods

ABSTRACT

Systems, methods, and boards for insulating building foundations are provided. The boards can be fiberglass, and the boards may have a pre-applied scrim. At least one coating can be provided on at least one face of the insulation boards. The boards can be applied to a portion of the building foundation above the grade line.

RELATED APPLICATIONS

This application claims priority to and any other benefit of U.S. Provisional Patent Application No. 60/591,216 filed Jul. 26, 2004, which is expressly incorporated by reference herein.

BACKGROUND

Waterproofing and insulation of building foundations can be one goal for new or existing construction, and existing systems can provide waterproofing and/or insulation to building foundations. However, such systems can be difficult to install, and such systems may not provide adequate protection to an above grade portion of the foundation. Thus, there remains a need in the art for systems and methods of providing insulation and/or waterproofing to building foundations.

SUMMARY

In accordance with embodiments of the present invention boards are provided. The boards can comprise an insulation board substrate having a first surface and a second surface; and a planar scrim having an open structure secured to at least a portion of the insulation board substrate. The scrim is secured to the insulation board by placing the scrim in contact with a fiberglass woolpack and curing the woolpack such that the insulation board substrate with the scrim secured to the first surface is formed.

In accordance with further embodiments of the present invention, methods for producing boards are provided. The methods comprise providing a planar scrim having an open structure such that it is disposed on at least a portion of a first surface of a fiberglass woolpack and subsequently curing the fiberglass woolpack such that an insulation board substrate having the scrim secured to at least a portion of a first surface of said insulation board substrate is formed.

In accordance with embodiments of the present invention, systems for insulation of building foundations are provided. The systems comprise at least one insulation board comprising an insulation board substrate having a pre-applied scrim on at least a portion of a first face of the at least one insulation board substrate and a coating. The at least one insulation board is disposed for installing on a building foundation such that the at least one insulation board covers at least a portion of the building foundation above a grade line. The coating is disposed for applying to the first face of the insulation board substrate such that the coating provides waterproofing properties to the system.

In accordance with embodiments of the present invention, methods for providing aboveground insulation are provided. The methods comprise applying insulating boards to cover at least a portion of the aboveground portion of a building foundation and coating the insulating boards with an elastomeric coating after the insulating boards have been applied to the foundation.

In accordance with other embodiments of the present invention, methods for providing aboveground insulation are provided. The methods comprise applying a plurality of insulating boards each having a first face, a second face, a top edge, a bottom edge, and a pre-applied scrim on said first face to a building foundation such that the second face of each of the plurality of insulating boards is proximate to the building foundation and such that the plurality of insulating boards covers the foundation from at least proximate to a grade line of the foundation to proximate a sill plate of said building foundation. The methods further comprise fastening the insulating board proximate to the bottom edge to the foundation with a plurality of fasteners and applying mesh tape to the top edge of the insulating boards such that at least a portion of the mesh tape at the top edge of the boards contact one of the sill plate and a band board installed to the sill plate. The methods further comprise fastening the mesh tape to the sill plate or the band board with a plurality of fasteners and applying a coating over the insulating boards and the mesh tape.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

FIG. 1 is an illustration of a board in accordance with embodiments of the present invention; and

FIG. 2 is an illustration of a system in accordance with embodiments of the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention will now be described with occasional reference to specific exemplary embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a, an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.

The present invention provides boards that may be used in aboveground insulation or covering of foundations. The present invention provides systems and methods of insulating, finishing, or covering at least the aboveground portion of a foundation. The present invention provides kits for insulating, finishing, or covering at least the above ground portion of a foundation.

In accordance with embodiments of the present invention, insulation boards are provided and methods of making insulation boards are provided. The insulation boards comprise an insulation board substrate having a scrim that is applied to the insulation board substrate during the manufacture of the board. For purposes of defining and describing the present invention, the term “scrim” shall be understood as including any suitable planar woven, non-woven, polymeric, glass or other suitable scrim structure that may be applied to a board in order to enhance application of coatings to the board and/or provide reinforcement to a coating applied to the board. For example, as shown in FIG. 1, an insulation board 10 may comprise an insulation board substrate 12 having a first surface 14 and a second surface 16. The first surface 14 can have a scrim 18 applied to the first surface 14 during the manufacture of the insulation board 10. It will be understood that the scrim 18 can be applied to only a portion of the first surface 14. For example, the scrim 18 can be applied such that the edges of the scrim are proximate to the edges of the board 10. Alternatively, the scrim 18 can be applied such that the edges of the scrim are contiguous with the edges of the insulation board substrate 12.

The insulation board substrate 12 may be any suitable type of fiberglass insulation board. For example, the insulation board substrate may be a dense fiberglass board similar to the Owens Coming WARM-N-DRI® Foundation Board. The insulation board substrate 12 may have any suitable dimensions or thickness. The scrim 18 can be any suitable scrim that has an open structure that is open enough to allow coating to flow through the scrim 18. In one example, the open structure is an open weave or open mesh structure. In another example the open structure is a non-woven structure having interstices between at least some of the adjacent material fibers or threads. In one example, the scrim 18 can be made of a material having between about 30×30 to about 3×3 threads per inch. In another example, the scrim 18 can be made of a material having about 10×10 threads per inch. In another example, the scrim 18 can be a glass scrim having G37, G75, or G150 yams and a temperature resistant binder.

The scrim 18 can be secured to the insulation board substrate 12 in any suitable manner. In one example, the insulation board substrate 12 can be a fiberglass board, and the scrim 18 can be placed in contact with at least a portion of the top of the woolpack prior to curing the woolpack in a fiberglass drying and curing oven. It will be understood that any suitable manufacturing system can be used to produce the board 10 having the scrim 18. In one example, the woolpack having the scrim 18 in contact therewith can be compressed during the curing to form a dense board 10. In another example, the woolpack can be cured at a temperature between about 400° F. to about 600° F. or about 450° F. to about 500° F. The scrim 18 is secured to the board 10 during curing in the fiberglass drying oven. No other adhesives are necessary to secure the scrim 18 to the board 10. The pre-applied scrim 18 allows the board 10 to be easily installed on a structure and to have a coating immediately applied to the board 10. Thus, the additional step of installing a scrim over installed board is not required.

In accordance with other embodiments of the present invention, systems, kits, and methods for providing above ground insulation to foundations are provided. Referring to FIG. 2, a system 21 installed on a foundation 20 is illustrated. The exemplary foundation 20 has a wall portion 22, a sill plate 24, and a band board 26. It will be understood that any suitable foundation structure may be insulated in accordance with the present invention. The foundation has a portion 28 below the grade line 30 and a portion 32 above the grade line 30.

During the construction of a structure, both the below grade portion 28 and the above grade portion 32 can be exposed. In order to waterproof and insulate the above grade portion 32, a waterproof membrane 34 is applied to the wall portion 22 of the foundation 20 to within about 2 inches of the sill plate 24 or any openings 36. Alternatively, the waterproof membrane 34 can be applied to stop proximate to the grade line if it is desirable to maintain water permeability of the above-grade portion of the foundation 20. The waterproof membrane 34 can be any suitable membrane. For example, the waterproof membrane 34 can be an elastomeric spray-on polymer modified asphalt membrane such as a TUFF-N-DRI® membrane available from Tremco Barrier Solutions. The below grade portion 28 of the foundation 20 may be further insulated with an insulation board such as a WARM-N-DRI® Foundation Board (not shown). If the below grade portion 28 of the foundation 20 is insulated with an insulation board, the board will terminate below the grade line 30.

Insulation boards 10 having a pre-applied scrim 18 are prepared for installation by beveling the top edge 38 of the board at an angle of about 10° to about 60°. For example, the boards 10 are beveled at a 45° angle as shown. The beveled edge 38 provides a continuous water drainage plane once the board 10 is coated as discussed herein. The boards 10 are installed to cover the above grade portion 32 of the foundation. The boards 10 are also disposed around openings such as a window opening 36 in the foundation 20. The edges of the boards 10 around openings 36 can be beveled as appropriate to provide a better appearance or enhance water drainage once the boards 10 are coated as discussed herein. Alternatively, the edges of the board 10 may not be beveled around openings 36.

Additionally, the boards 10 can be installed to cover a portion of the sill plate 24 or the band board 26. In one example, the boards 10 can be installed to within about 1 inch above or about 1 inch below the sill plate 24. The boards 10 may also be installed to be below the grade line 30. In one example, the boards 10 can be installed to be at least about six inches below the grade line 30. The boards 10 may extend below the grade line 30 any suitable distance up to the frost line if desired. The boards 10 may have any suitable dimensions. For example, the boards 10 may be 4×8 foot boards. The boards 10 can be 1 3/16 inches thick, 2⅜ inches thick, or be of any other suitable thickness. In some applications, more than one run of boards 10 will be required to provide suitable coverage to the above grade portion 32 of the foundation 20 when the distance from the sill plate 24 to 6 inches below the grade line 30 exceeds the maximum height of the boards 10.

As an aid to installation, the boards 10 may be temporarily fixed to the foundation 20 during installation by using clips 40. In addition, one or more clips 40 can be installed on the sill plate 24 or the band board 26 prior to the installation of the boards 10 at any suitable interval. The clips 40 can be angled with an angle that matches the beveled edge 38 angle of the boards 10 and set to meet the board 10 at the proper top edge height, and the top 38 of the board 10 can be seated against the junction between the foundation 20 and the clip 40 to aid in installation. It will be understood that the clips 40 can be of any suitable dimension. For example, the clips 40 can be sized such that a large number of clips 40 are provided along a given foundation wall 22. Alternatively, the clips 40 can be sized to span an entire section of the foundation wall 22. The board 10 is fastened near the bottom 42 of the board 10 with a suitable number of mechanical fasteners 44. For example, one fastener 44 can be installed every two feet. When only one run of boards 10 is necessary, the fasteners 44 can be hidden below the grade line 30. If more than one run of boards 10 is necessary, the fasteners 44 above the grade line 30 can be spackled prior to coating as described hereinafter. Any suitable type of fasteners such as pneumatic or hand driven fasteners may be used.

Seams 46 between the boards 10 can be taped with a mesh tape 48. Additionally, openings 36 in the foundation can be taped with a mesh tape 48. Corner protectors can be applied. The top beveled edge 38 of the board 10 is also taped with a run of mesh tape 50 along the beveled edge 38 and onto the sill plate 24 or the band board 26. The mesh tape 50 on the sill plate 24 and/or the band board 26 is fastened with fasteners 52 to the sill plate 24 or the band board 26. This attachment of the mesh tape 50 to the sill plate 24 or the band board 26 obviates the need fasteners to fasten the top of the board 10 to the foundation 20 when coated as discussed herein.

Once the boards 10 have been installed, a coating (not shown) can be applied to cover the boards 10 and mesh tape 48, 50. It will be understood that the present invention is also directed to boards having a coating in accordance with the present invention whether or not the coating is applied in place as described herein. The coating can provide waterproofing properties to the insulation system. The coating can have a dry thickness of between about 10 to about 60 mils. For example, the coating may have a thickness of about 40 mils dry. This high thickness coating allows the surface to have a dimensional texture if desired. Additionally, the coating can provide a board 10 surface having enhanced damage resistance.

The coating may be any suitable high quality elastomeric coating. For example, the coating could be an acrylic, styrene-acrylic, vinyl-acrylic, vinyl, or other suitable polymer type coating. For example, Horizon™ coatings from Tremco Barrier Solutions may be used. In another example, the coating can be an elastomeric coating having cellulosic fibers as filler. For example, the coating can comprise about 25% to about 55% resin having 50% solids, about 25% to about 75% fillers and pigments, about 0% to about 40% water, and about 0% to about 6% additives. In another example, the coating can comprise 40% resin, 52% fillers and pigments, 5% water, and 3% additives. The resin can comprise an acrylic, styrene-acrylic, vinyl-acrylic, vinyl, or other suitable resin. The filler can comprise a particulate and/or fibrous filler, such as calcium carbonate, fly ash, and cellulose or other polymeric fibers or microspheres.

The coating can be a matte finish coating or an aggregate finish coating. For purposes of defining and describing the present invention, the term “matte finish coating” shall be understood as referring to a coating that does not contain a substantial amount of coarse aggregate material. For purposes of defining and describing the present invention, the term “aggregate finish coating” shall be understood as referring to a coating that contains coarse aggregate. For purposes of defining and describing the present invention, the term “coarse aggregate” shall be understood as referring to an aggregate that can produce a surface feature in the finish of the coating. Any suitable type of coarse aggregate may be used. For example, calcium carbonate aggregate may be used in the coating. In another example, an aggregate that has 0% passing through a 16 mesh sieve, 2% passing through an 18 mesh sieve, 64% passing through a 30 mesh sieve, 33% passing through a 40 mesh sieve, and 2% passing through a greater than 40 mesh sieve can be used.

When an elastomeric coating containing cellulosic fibers is used in conjunction with a fiberglass board 10, the coated surface displays a surprising degree of damage resistance to abrasion and puncture impacts and other types of damage. Without wishing to bound to any particular theory, it is believed that the fibers in the fiberglass board 10 reinforce the coating. It is also believed that the coating fibers may interact synergistically with the fiberglass fibers of the board 10 to produce a more damage-resistant coated board. This enhanced damage resistance is desirable because the boards 10 and coating may experience impacts from people, yard equipment, etc., during the life of the building.

The coating can be applied in any suitable manner. In one example, the coating is applied by spraying coating, such as a matte and/or aggregate coating, onto the insulation boards 10 and the mesh tape 48, 50. In another example, a two-step wet on wet process may be used. In the first step, a high-output airless sprayer may be used to apply a matte coating. In the second step, an air-atomized sprayer may be used to apply an aggregate coating on top of the wet matte coating. This two-step application procedure provides a fast wet-on-wet application of the coating. Additionally, the use of an aggregate coating provides increased damage resistance and aesthetic improvement to the insulation system 21. In one example, about 75% of the dry thickness of the coating may be a matte coating and about 25% of the dry thickness of the coating may be an aggregate coating. In another example, the ratio of the matte coating to the aggregate coating may be between about 1:4 to 4:1.

The coated boards 10 provide aboveground insulation. Additionally, the coated boards 10 provide a continuous water shedding plane on the foundation of a building. The coated boards 10 can also serve as a sill sealer because the seam between the sill plate 24 and the foundation 20 and/or the seam between the sill plate 24 and the band board 26 can be covered by mesh 50 and a coating. The insulation system 21 does not require the use of cementicious products. The coated boards 10 stop water from reaching the foundation 20, but the coated boards 10 are vapor permeable. Therefore, the insulation system 21 offers vapor permeable insulation of the foundation of buildings. It will be understood that the boards 10 and coatings of the present invention can be configured and installed to cover any building foundation.

It will be readily apparent to those skilled in the art that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification. 

1. A board, comprising: an insulation board substrate having a first surface and a second surface; and a planar scrim having an open structure secured to at least a portion of said insulation board substrate, wherein said scrim is secured to said insulation board by placing said scrim in contact with a fiberglass woolpack and curing said woolpack such that said insulation board substrate with said scrim secured to said first surface is formed.
 2. The board as claimed in claim 1 wherein said scrim is formed from a material having between about 3×3 to about 30×30 threads per square inch.
 3. The board as claimed in claim 2 wherein said scrim has about 10×10 threads per square inch.
 4. The board as claimed in claim 1 wherein at least one edge of said insulation board substrate is beveled.
 5. The board as claimed in claim 1 wherein said scrim is made from a material selected from at least one of a woven, non-woven, and polymeric material.
 6. The board as claimed in claim 1 wherein said scrim comprises a glass scrim.
 7. The board as claimed in claim 1 wherein said scrim is secured to said insulation board substrate without an adhesive.
 8. The board as claimed in claim 1 wherein said board has a top edge, a bottom edge, and first and second side edges, and wherein said scrim is applied such that edges of said scrim are proximate to said top, bottom, and first and second side edges of said insulation board substrate.
 9. The board as claimed in claim 1 wherein said scrim is disposed such that said scrim enhances application of a coating to said insulation board substrate.
 10. The board as claimed in claim 9 wherein said scrim is disposed to enhance application of an elastomeric coating.
 11. The board as claimed in claim 1 wherein said scrim is disposed such that said scrim provides reinforcement to a coating applied to said insulation board substrate.
 12. A method for producing a board, comprising: providing a planar scrim having an open structure such that said planar scrim is disposed on at least a portion of a first surface of a fiberglass woolpack; and subsequently curing said fiberglass woolpack such that an insulation board substrate having said scrim secured to at least a portion of a first surface of said insulation board substrate is formed.
 13. The method as claimed in claim 12 wherein said step of subsequently curing comprises curing said woolpack at a temperature between about 450° F. to about 500° F.
 14. The method as claimed in claim 12 wherein said step of subsequently curing further comprises compressing said woolpack during said step of subsequently curing.
 15. The method as claimed in claim 12 wherein said scrim is formed from a material having between about 3×3 threads to about 30×30 threads per square inch.
 16. The method as claimed in claim 15 wherein said scrim has about 10×10 threads per square inch.
 17. The method as claimed in claim 12 wherein the step of providing a scrim comprises providing a scrim having a top edge, bottom edge, and first and second edges on a woolpack having a top edge, bottom edge, and first and second edges, and wherein said scrim is disposed such that the edges of said scrim are proximate to the edges of the woolpack.
 18. The method as claimed in claim 12 wherein said step of providing a scrim further comprises providing a scrim having a structure through which an elastomeric coating can flow such that said elastomeric coating can contact said insulation board substrate. 